Maintenance Manual

Avon
gas generator and variants
Gas Fuelled
1535-161G, 162G, 170G & 171G

Publication ref CD-Av1535-GAS

Rolls-Royce Power Engineering plc

Ansty, Coventry CV7 9JR, England
Tel: +44 (0)24 7662 4000
Fax: +44 (0)24 7662 4666

 2000 Rolls-Royce plc

The information in this document is the property of Rolls-Royce plc and may not be copied, or
communicated to a third party, or used for any purpose other than that for which it is supplied
without the express written consent of Rolls-Royce plc.

Whilst this information is given in good faith, based on the latest information available to
Rolls-Royce plc, no warranty or representation is given concerning such information, which must not
be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any
of its subsidiary or associated companies.

Rolls-Royce Power Engineering plc, Registered office: Moor Lane, Derby DE24 8BJ
Printed in England Company number: 1305027, Registered in England Issued May 2000
 INDUSTRIAL AVON GAS GENERATOR
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CONTENTS

TITLE PAGE

WARNINGS

PREFACE

INFORMATION NOTE

ABBREVIATIONS AND EQUIVALENTS

LIST OF SUPPLIERS

CHAPTER 1 GENERAL DESCRIPTION

CHAPTER 2 DETAILED DESCRIPTION

CHAPTER 3 OPERATING INSTRUCTIONS

CHAPTER 4 OPERATIONAL CHECKS

CHAPTER 5 FAULT DIAGNOSIS

CHAPTER 6 PREVENTIVE MAINTENANCE

CHAPTER 7 CORRECTIVE MAINTENANCE

CHAPTER 8 COMPRESSOR CLEANING AND INHIBITING

CHAPTER 9 LIST OF SPECIAL TOOLS

CHAPTER 10 REMOVAL, PACKING, STORING AND

INSTALLATION

CHAPTER 11 CONDITION MONITORING

CHAPTER 12 ENDOSCOPE INSPECTION

CONTENTS

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WARNINGS

WARNING 1 - IGNITION SYSTEM

BEFORE COMMENCING ANY EXAMINATION OF THE GAS GENERATOR IGNITION

SYSTEM, ENSURE THAT THE LOW TENSION LEAD IS FIRST DISCONNECTED
FROM THE SUPPLY TO THE HIGH ENERGY IGNITION UNIT, AS THE HIGH
VOLTAGE ASSOCIATED WITH THE IGNITION PLUGS MAY PROVE LETHAL.
ALLOW TEN MINUTES TO ELAPSE BETWEEN DISCONNECTION AND THE
CHECKING OF ANY COMPONENT.

(1) SYSTEM SAFETY

ENSURE THAT ELECTRICAL CIRCUITS, FUEL, LUBRICATING OIL,

HYDRAULIC OIL AND FIRE EXTINGUISHING SYSTEMS ARE ISOLATED AND
SAFE IN ACCORDANCE WITH LOCAL ORDERS AND MAINTENANCE MANUAL
INSTRUCTIONS BEFORE COMMENCING ANY WORK ON THE EQUIPMENT.
LIVE FUNCTION TESTING MUST ONLY BE UNDERTAKEN BY AN
AUTHORISED COMPETENT PERSON.

(2) IGNITER/HIGH ENERGY IGNITION UNIT FUNCTION TESTING

IN ALL CASES A DRY MOTORING CYCLE MUST BE CARRIED OUT

INMMEDIATELY PRIOR TO FUNCTION TESTING IGNITERS, HIGH ENERGY
IGNITION UNITS OR THEIR RELATED CIRCUITS.

WARNING 2 - VITON SEALS EXPOSED TO HIGH TEMPERATURES

WHEN DISASSEMBLING COMPONENTS WHICH CONTAIN PARTS MANUFACTURED

FROM VITON THAT HAVE BEEN EXPOSED TO TEMPERATURES IN THE REGION
OF 400 DEG C (750 DEG F) OR HIGHER THE VITON DECOMPOSES
CHEMICALLY. ONE OF THE BY-PRODUCTS IS HYDROFLUORIC ACID WHICH IS
HIGHLY CORROSIVE AND ALMOST IMPOSSIBLE TO REMOVE ONCE IT HAS
CONTAMINATED THE SKIN.

THE FOLLOWING PRECAUTIONS SHOULD BE ADHERED TO:-

(1) SHOULD YOU BE REQUIRED TO INSPECT AND/OR REPLACE ANY

OVERHEATED COMPONENT MANUFACTURED FROM VITON UNDER NO
CIRCUMSTANCES PERMIT THE MATERIAL TO COME INTO CONTACT WITH
BARE SKIN.

(2) IF ANY ACID CONTAMINATION HAS TAKEN PLACE THE AFFECTED AREA
SHOULD BE DE-CONTAMINATED BEFORE WORK COMMENCES.

(3) ANY SKIN CONTAMINATION MUST BE TREATED WITH HYDROFLUORIC ACID

BURN JELLY AS SOON AS POSSIBLE AND MEDICAL ADVICE SOUGHT.

WARNINGS

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WARNING 3 - STEELGARD 521, 522, ARDROX 3961 AND CASTROL DWX24

INHIBITING FLUID VAPOUR HAZARD

OWING TO A POSSIBLE HEALTH HAZARD, CARE SHOULD BE TAKEN NOT TO

INHALE STEELGARD 521, 522, ARDROX 3961 AND CASTROL DWX24
INHIBITING FLUID VAPOUR, OR EQUIVALENT, WHEN INHIBITING GAS
GENERATORS. THIS COULD OCCUR WHEN A GAS GENERATOR IS AT REST OR
ON BARRING BUT IS OF PARTICULAR CONCERN WHEN USING AEROSOLS IN A
CONFINED SPACE. WHEN INHIBITING WITH STEELGARD 521, 522, ARDROX
3961 AND CASTROL DWX24 INHIBITING FLUID UNDER THESE CONDITIONS A
DRY GAUZE FACE AND NOSE MASK SHOULD BE WORN AS A PRECAUTIONARY
MEASURE. A FINE MIST OF STEELGARD 521, 522, ARDROX 3961 AND
CASTROL DWX24 INHIBITING FLUID OR EQUIVALENT, IN THE ATMOSPHERE
COULD BE READILY IGNITED (FLASH POINT 41 DEG C (110 DEG F)
(MINIMUM) OPEN CUP), THEREFORE ALL SOURCES OF IGNITION IN THE
PROXIMITY SHOULD BE EXTINGUISHED BEFORE INHIBITING IS CARRIED
OUT.

WARNING 4 - SYNTHETIC LUBRICATING OIL

THE SYNTHETIC LUBRICATING OIL USED IN THIS ENGINE CONTAINS

ADDITIVES WHICH, AFTER PROLONGED SKIN CONTACT, CAN BE TOXIC
THROUGH ABSORPTION.

WARNING 5 - SITE REGULATIONS

BEFORE WORKING ON ANY PART OF THE GENERATING SET, PERSONNEL MUST

ENSURE THAT ALL CURRENT SITE REGULATIONS ARE COMPLIED WITH.
PERSONNEL MUST ALSO OBTAIN PERMISSION FROM THE ENGINEER IN CHARGE
BEFORE ENTERING ANY OF THE EQUIPMENT ENCLOSURES.

WARNING 6 - ELECTRICAL SYSTEM ISOLATION

PRIOR TO ANY ELECTRICAL MAINTENANCE (EG CHANGING LIGHT BULBS)

WITHIN THE GAS GENERATOR PACKAGE IT IS IMPERATIVE THAT THE
APPROPRIATE FUSES ARE REMOVED OR THAT THE APPROPRIATE SYSTEM IS
SWITCHED OFF AT THE CONTROL PANEL, THEREBY ISOLATING THE
ELECTRICAL SYSTEM WHICH REQUIRES MAINTENANCE.

WARNING 7 - PERSONNEL ENTRY INTO GAS GENERATOR ENCLOSURE/TURBINE

HALL

A FAILURE OF THE GAS GENERATOR, PRIMARILY WHEN STARTING OR WHEN

OPERATING AT LOAD, MAY NOT BE CONTAINED WITHIN THE GAS GENERATOR
CASINGS. THIS IS A RISK OF INJURY OR POSSIBLE DEATH TO PERSONNEL
ENTERING THE GAS GENERATOR ENCLOSURE/TURBINE HALL WHILE THE GAS
GENERATOR IS OPERATING. IT IS RECOMMENDED THAT PERSONNEL DO NOT
ENTER THE GAS GENERATOR ENCLOSURE/TURBINE HALL WHEN THE GAS
GENERATOR IS OPERATING.

WARNINGS

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PERSONNEL WHO GO INTO THE ENCLOSURE/TURBINE HALL MUST ONLY DO SO

WHEN:-

(1) THE GAS GENERATOR IS NOT OPERATING

(2) THE GAS GENERATOR IS AT STABLE IDLE.

IN ADDITION IT IS RECOMMENDED THAT PERSONNEL DO NOT GO INTO

THE GAS GENERATOR ENCLOSURE/TURBINE HALL WHEN:-
(a) FAULT FINDING PROCEDURES ARE REQUIRED.
(b) ALARMS OR TRIPS HAVE OPERATED WHICH INDICATE A DANGER IN
THE ENCLOSURE/TURBINE HALL.
(c) IT IS THOUGHT THE INTEGRITY OF THE GAS GENERATOR IS
SUSPECT.

IF IT IS NECESSARY TO GO INTO THE GAS GENERATOR ENCLOSURE/TURBINE

HALL WHILE THE GAS GENERATOR IS OPERATING, THE PROCEDURES THAT
FOLLOW MUST BE OBEYED:-

(1) SUITABLE EAR PROTECTION MUST BE WORN.

(2) A "PERMIT TO WORK" SYSTEM MUST BE INSTALLED AND USED.

WARNING 8 - PERSONNEL ENTRY INTO AIR INTAKE PLENUM

PERSONNEL ARE NOT TO ENTER THE AIR INTAKE PLENUM AREA WHILST THE
GAS GENERATOR IS RUNNING.

WARNING 9 - PERSONNEL ENTRY INTO GAS GENERATOR ENCLOSURE/TURBINE

HALL DURING STARTER MOTOR OPERATION

NO PERSONNEL ARE TO BE ALLOWED INTO THE GAS GENERATOR

ENCLOSURE/TURBINE HALL DURING STARTER MOTOR OPERATION.

WARNING 10 - REMOVING MCDs WHILE RUNNING

IT IS RECOMMENDED THAT THE PRACTICE OF REMOVING MAGNETIC CHIP

DETECTORS (MCDs) WITH THE GAS GENERATOR RUNNING IS DISCONTINUED.

MCDs SHOULD ONLY BE REMOVED WITH THE GAS GENERATOR SHUT DOWN AND
OPERATIVES WEARING APPROPRIATE PROTECTIVE CLOTHING.

NOTE: Quantitative Debris Monitors (QDMs) which electronically

'count' debris particles, are available for Avon gas
generators. Use of QDMs precludes the need for manual
removal of MCDs. Rolls-Royce Power Engineering plc will
supply details of these units upon request.

WARNINGS

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WARNING 11 - TIME EXPIRED COMPONENTS

ROLLS-ROYCE POWER ENGINEERING PLC (RRPEplc) ARE CONCERNED WITH

THE GROWING TRADE IN LIFE EXPIRED COMPONENTS AND COMPONENTS
MANUFACTURED WITHOUT RRPEPLC APPROVAL. THE MANUFACTURE OF
COMPONENTS BY SUPPLIERS APPROVED BY RRPEplc IS SUBJECT TO RRPEPLC
QUALITY ASSURANCE CONTROLS TO ENSURE THAT COMPONENTS SOLD TO THE
CUSTOMER MEET THE RRPEplc SPECIFICATION. THE ORIGINAL DESIGN OF
THE COMPONENT WILL HAVE BEEN BASED ON YEARS OF OPERATING
EXPERIENCE OF THE GAS GENERATORS, THE USE OF APPROPRIATE
MATERIALS AND THE REQUIREMENT FOR SAFE OPERATION.

COMPONENTS MANUFACTURED WITHOUT RRPEplc APPROVAL MAY BE INFERIOR

IN QUALITY TO THAT OF THE ORIGINAL. EXTERNAL APPEARANCE MAY BE
SIMILAR BUT METALLURGICAL PROPERTIES, AND CONSEQUENT LIFE, MAY
NOT BE TO THE RRPEplc DESIGN INTENT. IT IS NOT POSSIBLE TO
PREDICT LIVES FOR THESE COMPONENTS BUT A CONSIDERABLE REDUCTION
COMPARED TO GENUINE PARTS COULD BE EXPECTED.

THE USE OF THESE COMPONENTS, COULD RESULT IN SUBSTANTIAL REPAIR

COST AFTER PREMATURE FAILURE, OR THE POSSIBILITY OF SERIOUS
INJURY OR EVEN LOSS OF LIFE OF OPERATING PERSONNEL.

A SIMILAR SITUATION EXISTS WITH THE REUSE OF LIFE EXPIRED

COMPONENTS SUCH AS TURBINE AND COMPRESSOR BLADES AND DISCS.
WHEREAS RRPEplc APPROVED REPAIR FACILITIES HAVE PROCEDURES IN
PLACE COVERING LIFE EXPIRED COMPONENTS, IT IS SUSPECTED THAT
CERTAIN NON APPROVED REPAIRERS, POSSIBLY UNWITTINGLY, HAVE BEEN
RETURNING THESE COMPONENTS, COSMETICALLY REFURBISHED TO AN
UNSUSPECTING MARKET.

RRPEplc ACCEPTS NO RESPONSIBILITY FOR ANY FAILURE OR DAMAGE DUE

TO FITMENT OF LIFE EXPIRED COMPONENTS OR COMPONENTS OBTAINED FROM
A NON-RRPEplc APPROVED SOURCE.

IN ORDER TO PROTECT AGAINST THE POSSIBLE USE OF LIFE EXPIRED OR

NON-RRPEplc APPROVED COMPONENTS, THE OPERATOR CAN:-

(1) ENSURE THAT ALL GAS GENERATORS AND POWER TURBINES ARE
SERVICED, REPAIRED AND OVERHAULED BY RRPEplc APPROVED
PERSONNEL AND REPAIR FACILITIES.

(2) ENSURE THAT WHERE NEW OR REPLACEMENT COMPONENTS ARE FITTED,

THEY ARE GENUINE RRPEplc PARTS AND THAT THEY ALL CARRY
RRPEplc PART NUMBERS IN LOCATIONS AND IN THE MANNER AS
PRESCRIBED BY RRPEplc (INFORMATION ON THIS WILL BE SUPPLIED
TO RECOGNISED OWNER/OPERATORS).

(3) INSTRUCT THE OVERHAUL BASE TO DEFACE ANY LIFE EXPIRED

COMPONENTS IN SUCH A WAY AS TO MAKE COSMETIC REFURBISHMENT
IMPOSSIBLE, EG. A NOTCH CUT OR GROUND INTO THE LEADING EDGE
OF A BLADE AEROFOIL.

WARNINGS

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PREFACE

This Manual has been compiled to provide a comprehensive

understanding of the gas generators specified on the title page.
It contains all the information necessary for maintenance between
overhauls.

It is essential that the work detailed in this Manual is carried

out by trained and competent personnel.

It is a requirement that users of this Publication be familiar

with and observe local Health and Safety Regulations and
requirements that may affect the publication contents.

Throughout this Manual the left or right-hand side of the engine

is identified by viewing the engine from the rear.

To allow operators to have the benefit of the Rolls-Royce

amendment service, every page is dated and the Manual is bound in
loose-leaf fashion so that any page can easily be removed and
replaced. When, as a result of modification changes or changes in
technique an amendment to the Manual is required, amended pages
will be issued for each manual copy held.

Amendments will be covered by Rolls-Royce Publication Transmittal

Letters, and in normal circumstances these will be serial
numbered. Because of variations in installations, appendices
dealing with installation peculiarities will be issued as
necessary. Such appendices, because of their restricted
application, will have limited distribution; to avoid disparity
in normal transmittal numbering, appendices will be issued under
'Supplementary Transmittal Letters' without numbers.

Every Transmittal Letter will give instructions for removal of

the out-of-date pages and insertion of the up-to-date pages and
will give a brief technical reason for the change.

A page headed 'ROLLS-ROYCE TRANSMITTALS' is provided at the front

of the Manual and, if an entry is made on each occasion of
amendment, continuity of amendment is assured. Supplementary
Transmittal Letters should also be entered on the record page,
but in place of a transmittal number the abbreviation 'Supp.' may
be inserted. Each Transmittal Letter will be punched and trimmed
in the same fashion as the amended pages and can be inserted in
serial sequence in the extreme front of the Manual to provide a
brief technical history. Each amended page will have a black line
or lines on the right-hand margin to indicate the extent of the
amended material.

PREFACE

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When extremely urgent information must be incorporated in the

Manual as quickly as possible, a Temporary Revision will be
issued to operators; the Temporary Revision will be printed on
yellow paper, and will not be covered by a Transmittal Letter.
Instructions for incorporation will be printed on each Temporary
Revision and the Revision is to be inserted facing, not
replacing, the page it amends. Later, a normal amendment will be
issued to replace both the Temporary Revision and the affected
page. Temporary Revisions will not be frequent occurrences and
the procedure is retained only to cater for conditions of extreme
urgency.

The effect of modifications will be included in this Manual by

amending the affected pages. The modification data itself,
however, will be issued to operators in a separate Modification
Leaflet Manual (AvGG).

PREFACE

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INFORMATION NOTE

PLEASE REFER TO THE DETAILS GIVEN BELOW TO CONTACT YOUR NEAREST

CUSTOMER SUPPORT ORGANISATION REGARDING ANY QUERIES CONCERNING
THE INFORMATION WITHIN THE MAINTENANCE MANUAL PUBLICATION.

COMMUNICATION

If you have any queries all communication should be addressed

to:-

Technical Support Manager

Customer Support Department
Rolls-Royce Power Engineering plc
Ansty
COVENTRY CV7 9JR

Telephone: 024 7662 3055 or 7662 4392

Fax: 024 7662 4017

Or North American Region Operators:-

Customer Support Department

Rolls-Royce (Canada)
9904 Cote de Liesse Road
Lachine
Quebec
CANADA H8T 1A1

Telephone: 514 636 0964

Fax: 514 631 1849

INFORMATION NOTE

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ABBREVIATIONS AND EQUIVALENTS

The abbreviations and equivalents in the following list are used

in Rolls-Royce publications, particularly in tables and
illustrations. In instances where an abbreviation has more than
one possible meaning, the context in which it appears will
indicate the meaning intended.

A ampere(s)
abs absolute
ac )
or ) alternating current
AC )
act actual
AIT air intake temperature
alt alternative
amp ampere(s)
AMP amplifier
amp hr )
or ) ampere hour(s)
A hr )
AMS American Material Specification
approx approximately
AR Avon repair
A/R )
or ) as required
AR )
ARS Avon repair scheme
ASG American Specification Group
assy assembly
ASTM American Society for Testing Materials
AWG American Wire Gauge
Av average

ABBREVIATIONS

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BA British Association
BDC bottom dead centre
Bhn Brinell hardness number
bhp brake horsepower
BOG British Oxygen Gases
BS British Standard
BSF British Standard Fine
BSP British Standard Pipe
BSW British Standard Whitworth
B.Th.U. British Thermal Unit
BVCU Bleed valve control unit

C centigrade
C circumferential
cal calorific
cat category
C/bore )
or ) counterbore
C/Bore )
cent centigrade
cf compare
CF current flow
CFH cubic feet per hour
CFM cubic feet per minute
Chap )
or ) chapter
ch )
CH hd )
or ) cheesehead
ch/hd )
chmf chamfer
cm centimetre(s)
cm2 square centimetre(s)
cm3 cubic centimetre(s)
corr corrected
CP change pressure
cp/hd cuphead
cps cycles per second

ABBREVIATIONS

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CSD constant speed drive

Csk/hd )
or ) countersunk head
csk/hd )
CSU constant speed unit
ctrs centres
cu ft. cubic foot
cu in. cubic inch
cwt Hundredweight = 112 pounds
c/w complete with

dc )
or ) direct current
DC )
deg degree(s)
∆ increment or finite difference
(the Greek letter delta)
DERD Directorate of Engineering, Research
and Development
dia diameter
dim dimension
doz dozen = 12
drg drawing
DTD Directorate of Technical Development
DTI dial test indicator

ECT exhaust cone temperature

eff effective
eg for example
EGT exhaust gas temperature
emf )
or ) electromotive force
EMF )
Est estimated
EU European

ABBREVIATIONS

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F Fahrenheit
FCOC fuel cooled oil cooler
FCU fuel control unit
FIM full indicated movement
FIR full indicated reading
fl oz. fluid ounce(s)
ft foot, feet
ft2 square feet
ft3 cubic feet
ft3/hr cubic feet per hour
ft3/min cubic feet per minute
ft/sec )
or ) feet per second
ft per sec )
FP Flash point

gall gallon(s)
gall/min gallons per minute
gm gramme(s)
gph gallons per hour
gpm gallons per minute
gross 144 (quantity)

Hex hd hexagon head

h hour(s)
HE high energy
HF high frequency
Hg mercury
hp horsepower
HP high pressure
hr hour(s)
HT high tension

ABBREVIATIONS

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ID )
or )
id ) inside diameter
or )
i/dia )
ie that is
IGV intake guide vane
Imp Imperial
in. inch = 25.4 millimetres
ins. inches
in2 square inch(es)
in3 cubic inch(es)
in Hg. inches of mercury
intf interference
IP intermediate pressure
ISA International Standard Atmosphere

JP jet pipe
jpt )
or ) jet pipe temperature
JPT )

kc/s kilocycles per second

Kg )
or ) kilogrammes
kg )
kg cm2 kilogrammes per square centimetre
km kilometre(s)
kV kilovolt
kW kilowatt

ABBREVIATIONS

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l litre(s)
L longitudinal
lb pound = 16 ounces
lbf ft. pounds force foot, feet
lbf hr. pounds force per hour
lbf in. pounds force inch(es)
lbf in2 pounds force per square inch
lbf min pounds force per minute
lbf sec pounds force per second
lbf sq in. pounds force per square inch
LH left-hand
LP low pressure
LP Lucas overhaul pressure (in TSD594)
LT low tension

m metre(s)
mA milliampere(s)
max )
or ) maximum
Max )
m/c )
or ) machine
M/C )
mg milligramme
min(s) minute(s)
min minimum
Mk. mark(s)
ml millilitre
mm millimetre
Mod modification
M of T Ministry of Transport

ABBREVIATIONS

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N gas generator speed

NA not applicable
or
North American
NGV nozzle guide vane
NHA next highest assembly
No. number
nom nominal
Nos. numbers

O/B overboard
OAT outside air temperature
OD )
or )
od ) outside diameter
or )
o/dia )
OGV outlet guide vane
% per cent
O.P. Overhaul Process (TSD594)
O/S oversize
OTP of true position
oz ounce = 28.35 grammes

P
p, pp page, pages
P0 atmospheric pressure
P1 compressor inlet pressure
P2 compressor delivery pressure
P3 turbine inlet pressure
P4 turbine outlet pressure
para paragraph
PCD pitch circle diameter
PCR pitch circle radius
PM )
or ) Pre-Modification
Pre-Mod )

ABBREVIATIONS

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Pr pair
psi pounds per square inch
pt pint = 0.568 litre
pt hr. pints per hour
PV progressively variable
PVC polyvinylchloride

qt quart
qty quantity

R radial
rad radius or radian
Ref )
or )
REF )
or ) reference
RF )
or )
ref )
reqd required
RH right-hand
RPM )
or )
rpm ) revolutions per minute
or )
rev/min )
RRMS Rolls-Royce material specification

ABBREVIATIONS

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sec second(s)
Sect. section
sfc specific fuel consumption
SG )
or )
SP GR ) specific gravity
or )
sp gr )
shp shaft horsepower
SL shelf life
SOC shut off cock
Spec specification
spl spool
sq in. square inch
sq ft. square feet
std standard
SWG Standard Wire Gauge (British Imperial)
6 SWG = 0.1920 in.
7 SWG = 0.1700 in.
8 SWG = 0.1600 in.
9 SWG = 0.1440 in.
10 SWG = 0.1280 in.
11 SWG = 0.1160 in.
12 SWG = 0.1040 in.
13 SWG = 0.0920 in.
14 SWG = 0.0800 in.
15 SWG = 0.0720 in.
16 SWG = 0.0640 in.
17 SWG = 0.0560 in.
18 SWG = 0.0480 in.
19 SWG = 0.0400 in.
20 SWG = 0.0360 in.
21 SWG = 0.0320 in.
22 SWG = 0.0280 in.
23 SWG = 0.0240 in.
24 SWG = 0.0220 in.

ABBREVIATIONS

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T transverse
T0 atmospheric temperature
T1 compressor inlet temperature
T2 compressor outlet temperature
T3 turbine inlet temperature
T4 turbine outlet temperature
TB threading bar
TDC top dead centre
tehp total equivalent horsepower
temp temperature
thds thousand
TIM total indicated movement
TIR total indicated reading
tol tolerance
TPI threads per inch
Trop tropical
TTC top temperature control

UHF ultra high frequency

UK United Kingdom
UNC unified thread, coarse
UNF unified thread, fine

V volt(s)
VHF very high frequency
viz. namely
vol volume
VPN Vickers pyramid number (hardness test)

ABBREVIATIONS

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W watt(s)
Whit Whitworth
Wt weight
w/m water methanol

yd yard

ABBREVIATIONS

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LIST OF SUPPLIERS

Ardrox Ltd. Dalton and Co. Ltd.

Furlong Road Silkolene Oil Refining
Bourne End Belper
Buckinghamshire SL8 5AJ Derbyshire DE5 1WF
Great Britain Great Britain

B & B Chemicals Co. Ltd. Dow Chemical Co. (UK) Ltd.

P.O. Box 796 Cross Bank Road
Miami Kings Lynn
Florida 33166 Norfolk PE30 2SD
U.S.A. Great Britain

B & B Chemical Company Driclad Ltd.

c/o Mullet Luchtvaart BV Staplehurst Road
Geboner 145 Sittingbourne
Schiphol East Kent
Holland Great Britain

Brent Chemical Products Ltd. Esso Petroleum Co. Ltd.

Commerce Road Esso House
Brentford 90 Victoria Street
Middlesex TW8 8LJ London SW1 5JW
Great Britain Great Britain

Burmah-Castrol Ltd. Exxon Co. U.S.A.

Burmah House 800 Bell Avenue
Piper Way Houston
Swindon Texas 77002
Wiltshire SN3 1RE U.S.A.
Great Britain

Cadulac Chemicals Ltd. Imperial Chemical

Old Boston Trading Estate Industries Ltd.
Penny Lane I.C.I. House
Haydock Millbank
St. Helens London SW1P 3JJ
Lancashire WA11 9SG Great Britain
Great Britain
Indestructable Paint
J. Chadwick & Sons Ltd. Co. (1978) Ltd.
Warrington 43A The Avenue
Lancashire WA1 2DY Acocks Green
Great Britain Birmingham B27 6NG
Great Britain
Joseph Crossfield & Sons Ltd.
P.O. Box 26 International Paint Co.Inc.
Liverpool Road 21 West Street
Warrington New York
Lancashire WA5 1AB New York City 10006
Great Britain U.S.A.

LIST OF SUPPLIERS

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Marston Lubricants Ltd. Rocol Ltd.

7-11 Naylor Street Wakefield Road
Liverpool L3 6DS Swillington
Great Britain Leeds LS26 8BS
Great Britain

Med-Lab Limited Shell Mex and BP Ltd

Copeland Street P.O. Box 148
Derby DE1 2PU Shell Mex House
Great Britain London WC2R 0DX
Great Britain

Midland Silicones Ltd. Turco Chemical

Barry Products Ltd.
Glamorgan Brunel Road
Great Britain Earlstrees Industrial Est.
Corby
Northants NN17 2JW
Great Britain

Mobil Oil Company Ltd. Vapor-Tek Ltd.

Mobil House Fairclough Street
54/60 Victoria Street Great Lever
London SW1E 6QB Bolton BL3 2AF
Great Britain Great Britain

Plus-Gas Co. Ltd. W.R. Sales and

Sterling Road Marketing Ltd.
Acton Toronto
London W3 8DN Ontario M3B 1W7
Great Britain Canada

P.P.G. Industries (UK) Ltd.

Aviation and Defence Coatings
Rotton Park Street
Ladywood
Birmingham B16 0AD
Great Britain

Rocep-Lusol
24 Reidvale Street
Glasgow G31 1SW
Scotland

LIST OF SUPPLIERS

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 INDUSTRIAL AVON GAS GENERATOR
MAINTENANCE

CHAPTER 1
GENERAL DESCRIPTION

CONTENTS

Para

GAS GENERATOR DATA 1

Type of Gas Generator 1.1
Compressor 1.2
Combustion System 1.3
Turbine 1.4
Fuel System 1.5
Lubrication System 1.6
Sealing and Cooling Air System 1.7
Anti-Icing System 1.8
Starter System 1.9
Handling Data 1.10
Instruments 1.11
Mechanical Features 1.12

GAS GENERATOR 2
Cooling and Sealing 2.1
Gas Generator Mountings 2.2
Exhaust unit fitted 2.2.1
No exhaust unit (close-coupled) 2.2.2
Starting 2.3
Combustion System 2.4
Airflow Control System 2.5
Lubrication 2.6
Anti-Icing System 2.7
Gas Flow and Energy Levels 2.8
Control of Gas Generator Power and RPM 2.9

ILLUSTRATIONS
Fig Page
1 Internal description 5/6
2 Gas generator - Left-hand view 9
3 Gas generator - Right-hand view 9
4 Gas flow diagram 13/14

CONTENTS

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CHAPTER 1
GENERAL DESCRIPTION

1 GAS GENERATOR DATA

1.1 Type of Gas Generator Straight flow gas turbine

Direction of rotation Anti-clockwise viewed from

rear

1.2 Compressor 17-stage axial flow,

incorporating automatic
air bleed valves and
progressively variable
intake guide vanes

Compression ratio 10:1 nominal

1.3 Combustion System Annular casing enclosing

eight interconnected flame
tubes

Flame tube numbering Anti-clockwise viewed from

rear, No.1 at top left-
hand position

1.4 Turbine Three-stage axial flow

1.5 Fuel System

Type of fuel Hydrocarbon gas

Fuel control unit Refer to the Plant

Manufacturer's Manual

Fuel burners Detachable, emitting

conical spray

1.6 Lubrication System Refer to Plant

Manufacturer's Manual

Oil specification See Chapter 6

Oil pressure See Chapter 3

GENERAL DESCRIPTION

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1.7 Sealing and Cooling Air Air tapped from stage 3 of

System the compressor is used to
seal the main bearings.
Air tapped from stage 15
is used to cool the Avon
turbine components. Air
tapped from stage 8 is
available to seal the
power turbine bearings

1.8 Anti-Icing System Hot air from stage 15 of

the compressor through an
electrically actuated
valve to the air intake
struts, intake guide vanes
and starter fairing

1.9 Starter System Initial rotation by

externally mounted or
112 volt DC starter motor.
Combustion initiated by
two igniter plugs,
igniting the fuel spray
from the burner in No.3
and No.6 flame tubes

1.10 Handling Data

Maximum diameter 48 inches (1220 mm.)

approximately
Overall length 129 inches (3277 mm.)
approximately
(Mk.161G/162G)
116 inches (2946 mm.)
approximately
(Mk.170G/171G)
Centre of gravity Approximately 29.5 inches
(749 mm.) forward of the
rear trunnion centre line
(Mk.161G/162G)
Approximately 31 inches
(787 mm.) forward of the
rear trunnion centre line
(Mk.170G/171G)
Weight 3,450 pounds (1565 kg.)
approximately
(Mk.161G/162G)
3,350 pounds (1520 kg.)
approximately
(Mk.170G/171G)

GENERAL DESCRIPTION
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1.11 Instruments

Gas generator speed indicator Electro-magnetic pick-up

Gas generator exhaust Eight thermocouples in the

temperature (T4) indicator exhaust unit
(Mk.161G/162G)

Eight thermocouples in the

free power turbine inlet
ducting (Mk.170G/171G)

Low oil pressure warning Pressure tapping provided

on the filter housing and
connection block for
connection to the plant
mounted low oil pressure
warning switch

Oil pressure indication Pressure tapping provided

on the filter housing and
connection block for
connection to the plant
mounted oil pressure
indicator

Anti-icing indication Pressure tapping provided

downstream of the anti-
icing valve for connection
to the plant mounted anti-
icing selection indication
switch

Vibration indicator Vibrometer CE134

accelerometer on the
left-hand side of the
compressor casing.

Vibrometer CE134
accelerometer on the
right-hand side of the
compressor outlet casing

Gas generator over- Over-temperature detector

temperature indicator is mounted in:

Cooling air outlet vent

NOTE: Not all these instruments will be found on every

installation.

GENERAL DESCRIPTION

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KEY TO FIGURE 1

AIR INTAKE 31. Internal Wheelcase Rear

Half
1. Starting Drive Fairing 32. Compressor/Turbine Coupling
2. Starter/Starter Drive
3. Intake Guide Vanes COMBUSTION CHAMBER
4. Anti-Icing Hot Air Tube
5. Front Bearing Housing 33. Flame Tube Interconnector
Support Strut 34. Combustion Chamber Heat
6. Air Intake Extension Shield
7. Intake Anti-Icing Manifold 35. Turbine Shaft
8. Anti-Icing Hot Air 36. Rear Bearing Housing
Delivery Pipe 37. Burner Head
9. Front Main Bearing 38. Burner Feed Arm
10. Intake Guide Vane 39. Flame Tube Locating Pin
Actuating Ring 40. Combustion Chamber Air
Casing
COMPRESSOR 41. Combustion Casing Adjusting
Washer
11. Compressor Rotor Blades 42. Rear Bearing Cooling Air
12. Compressor Rotor Blade Holes
Retaining Pin 43. Cooling Air Blanking Disc
13. Compressor Front Shaft 44. Rear Main Bearing
14. Anti-Icing Air Discharge 45. Flame Tube Discharge Nozzle
Valves 46. Cooling Air Discharge Tube
15. Vortex Reducer for Cooling
Air TURBINE
16. Cooling Air Holes
17. Compressor Rotor Disc 47. IP Turbine Shroud Cooling
Driving Splines Air Tube
18. Compressor Stator Blade 48. IP Nozzle Guide Vanes
Locating Ring 49. LP Turbine Wheel Securing
19. Rotor Disc Flexible Hub Bolt
50. HP Turbine Cooling Air Pipe
COMPRESSOR OUTLET CASING 51. Turbine Cooling Air Pipe
52. Outer Air Seal Carrier
20. Compressor Final Stage 53. Air Guide Plate
Disc 54. HP Nozzle Guide Vanes
21. Centre Main Bearing Front 55. Cooling Air Manifold
Air Seal
22. Compressor Rear Shaft 56. HP Turbine Blades
57. IP Turbine Blades
Flange 58. Front Interstage Seal
23. Final Stage Seal Vent 59. Rear Interstage Seal
Compartment 60. LP Turbine Blades
24. Centre Main Bearing 61. LP Turbine Wheel Securing
25. Centre Main Bearing Front Nut
Oil Seal 62. Exhaust Unit Insulation
26. Compressor Final Stage Plate
Air Seal 63. LP Nozzle Guide Vanes
27. Compressor Outlet Guide 64. Cooling Air Outlet
Vanes 65. LP Turbine Casing
28. Flame Tube Snout
29. Internal Wheelcase Front EXHAUST UNIT
Half
30. Internal Wheelcase Driving 66. Exhaust Unit Inner Cone
Gear 67. Thermocouple

GENERAL DESCRIPTION

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FIG 1 INTERNAL DESCRIPTION

GENERAL DESCRIPTION

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1.12 Mechanical Features

The Avon gas generator has a three-stage turbine

driving a 17-stage compressor (Fig 1).

The main carcase of the gas generator is formed by a

number of basically circular casings secured together to
form the rigid structure. The concentricity and radial
alignment of the structure is maintained by spigots,
dowels and close fitting bolts. The rotating assembly,
which consists of the compressor and turbine, is supported
in ball and roller bearings and is dynamically balanced to
ensure smoothness of operation.

The principal units of the gas generator, taken in

sequence from front to rear (Figs 2 and 3), are the air
intake and front bearing housing surrounded by the anti-
icing air manifold, the compressor, the compressor outlet
casing which houses the internal wheelcase, the combustion
air casing which houses the eight combustion chambers, the
nozzle box and turbine housing and the exhaust unit. To
the exhaust unit is attached the exhaust transition
section which leads the gas flow to the power turbine.

Some marks of gas generator have a close-coupled

arrangement which eliminates the exhaust unit and
transition section and enables the gas generator to be
connected directly to the power turbine casing.

The air intake and front bearing housing, the

compressor casings and the internal wheelcase are
manufactured from various grades of light alloy. The
compressor outlet casing, the combustion air casing, the
nozzle box, the exhaust unit and the transition section,
as these are subjected to higher temperatures, are
manufactured from various grades of steel.

Due to the wide divergence of temperature and the

variety of materials used the gas generator is designed to
accommodate thermal expansion. For instance, the nozzle
guide vanes are free to move in their locations so that
expansion when running hot does not distort the nozzle box
and the turbine shroud rings. The combustion chamber flame
tubes are secured only at the front and are free to slide
in the nozzle box.

Most of the joints between the main casings are in a

state of tension, and to ensure adequate tightness of the
joints under running conditions the retaining nuts are
torque loaded to a specified poundage. Controlled
tightening is also applied to nuts retaining gears and
bearings, and to the bolts securing the compressor and
turbine to their driving flanges.

GENERAL DESCRIPTION

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KEY TO FIGURE 2

1. Front Bearing Housing and Anti-Icing Air Manifold

2. Stage 7 Bleed Valve
3. Anti-Icing Air Valve
4. Fuel Manifold
5. Nozzle Box and Turbine Housing
6. Exhaust Unit (Mk.161G only)
7. Cooling Air Outlet
8. Lubricating Oil Connection Block
9. Hydraulic Oil Connection Block
10. Air Connection Block
11. Compressor

KEY TO FIGURE 3

1. Thermocouples (Mk.161G only)

2. Rear Mounting Trunnion
3. Front Suspension
4. Stage 4 Bleed Valve
5. Intake Guide Vane Ram and Bleed Valve Control Unit
6. Compressor Outlet Casing
7. Combustion Air Casing
8. Cooling Air Outlet

GENERAL DESCRIPTION

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FIG 2 GAS GENERATOR - LEFT-HAND VIEW

FIG 3 GAS GENERATOR - RIGHT-HAND VIEW

GENERAL DESCRIPTION

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The rotating assembly of the gas generator is

subjected to both radial and axial stresses. The radial
stresses result from large centrifugal forces imposed by
the high operating rpm and mass of the rotating assembly.
The axial loads on the rotating assembly results from the
action of the gas stream. The turbine wheels tend to move
rearwards because of the pressure drop across the blades.
The compressor rotor tends to move forward due to the
increase of pressure across each stage of blades. It is
the function of the centre bearing to take the resultant
axial loads imposed by both the turbine and the
compressor.

2 GAS GENERATOR

2.1 Cooling and Sealing

To prevent the transfer of heat from the gas stream

to vital components within the gas generator and to
minimise thermal stresses, cooling air is tapped from the
compressor and conveyed to the gas generator components.
Air at compressor delivery temperature is used to cool the
turbine, air from an intermediate stage of the compressor
is used to cool the components not in direct contact with
the gas stream.

Throughout the gas generator there are several

clearances between stationary and rotating parts and at
these points seals, pressurised by the cooling air from
the compressor, are used to prevent leakage of air, oil or
hot gases into the gas generator. Because of the high
speeds and temperatures involved, the seals are mostly of
the multi-grooved, self-clearing or thread type.

2.2 Gas Generator Mountings

2.2.1 Exhaust unit fitted

The gas generator is supported by two mounting

trunnions attached to the nozzle box and two flexible
front mountings attached to the compressor casing. The
axial and circumferential forces imposed by the gas
generator are absorbed by the mounting trunnions. The two
flexible front suspension mountings, while supporting the
front of the gas generator, permit limited movement to
accommodate expansion and torque reaction from the
rotating assembly.

GENERAL DESCRIPTION
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2.2.2 No exhaust unit (close-coupled)

The gas generator has a close-coupled arrangement

which allows the gas generator to be supplied without an
exhaust unit thereby reducing the overall length to
provide a compact unit. The rear mounting flange is
rigidly connected to the power turbine casing, the weight
of the gas generator being taken on the rigid mounting
flange and the two flexible front suspension mountings
attached to the compressor casing. The axial and
circumferential forces imposed by the gas generator are
absorbed by the rigid mounting flange. The two flexible
front suspension mountings, while supporting the front of
the gas generator, permit limited movement to accommodate
expansion and torque reaction from the rotating assembly.

2.3 Starting

The gas generator is rotated initially either by an

external starter connected by a shaft to the starter drive
coupling or by a gas generator mounted electric starter,
mounted on the front of the compressor.

When the gas generator attains suitable speed,

combustion is initiated by means of two high energy
igniter plugs located in two of the combustion flame
tubes. The gas generator then starts to accelerate through
the minimum self-sustaining rpm, after which the starter
motor is deactivated as the gas generator continues to
accelerate to idling rpm.

The starting cycle is controlled throughout by an

automatic timing panel in the plant system.

2.4 Combustion System

The gaseous fuel is injected into the combustion

flame tubes through eight fuel burners, one in each flame
tube. The flow of gaseous fuel is controlled by an
externally located fuel control system. For details of
this system, refer to the Plant Manufacturer's Manual.

2.5 Airflow Control System

The airflow through the compressor is controlled by a

ring of moveable guide vanes fitted across the intake of
the compressor and by two bleed valves fitted to the
compressor casing. The vanes and bleed valves enable the
gas generator to operate smoothly at low rpm outside its
most efficient speed range.

GENERAL DESCRIPTION

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2.6 Lubrication

Gas generator lubrication is effected by a constant

pressure oil system using a low viscosity oil. The oil
system is located in the plant and lubricating oil is
conveyed to and from the gas generator via a connection
block mounted on the gas generator. For further details
refer to the Plant Manufacturer's Manual.

2.7 Anti-Icing System

To prevent ice from forming in the gas generator air

intake when operating in icing conditions, an electrically
controlled anti-icing system conveys hot air from the
compressor to heat the air intake casing, the starter
fairing, the intake guide vanes and the front stage of
compressor stator blades. If an external starter is
fitted, hot air from the compressor is used to prevent ice
formation on the drive tube from the external starter
motor.

2.8 Gas Flow and Energy Levels

The gas generator induces air from the atmosphere,

compresses it then heats it by adding and burning fuel in
the combustion flame tubes. The resultant expansion forces
the gases rearward through the gas generator turbine,
where some of the energy of expansion is used by the
turbine to drive the compressor and the accessories. The
gases continue to flow rearward, where the remaining
energy is extracted in driving the power turbine.

Fig 4 shows the energy imparted to and extracted from

the air/fuel stream in its passage through the gas
generator, the changes in pressure, temperature and
velocity being charted at each stage of the gas generator.
The chart in Fig 4 is given for reference only and depicts
a gas generator at maximum permitted rpm discharging
through an ideal final nozzle; the actual values vary with
rpm and with the design characteristics of the power
turbine.

2.9 Control of Gas Generator Power and RPM

At any given condition of barometric pressure and

ambient air temperature, gas generator power is a function
of gas generator rpm. Power output is controlled
automatically by regulating the fuel supply and thereby
regulating the rpm. This is effected by the externally
mounted fuel control system; refer to the Plant
Manufacturer's Manual for further details.

GENERAL DESCRIPTION

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FIG 4 GAS FLOW DIAGRAM GENERAL DESCRIPTION

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